Trans-IND Training material, courses and workshops deployment

plantcitybusinessUrban and Civil

Nov 26, 2013 (3 years and 11 months ago)

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CONTENTS:

1


New

Industrialised

Construction

Process

for

transport

infrastructures

based

on

polymer

composite

components

Large
-
scale integrating
project

CP
-
IP 229142
-
2

Start: 2009
-
06
-
01

Duration: 48 months

Project
co
-
funded by the European Commission

within the Seventh Framework Programme (2007
-
2013)

Training material, courses and
workshops deployment

Training Material


2



Table of contents

1.

Training programme____________________________________________________________4

1.1

Training resources__________________________________________________________ 4

1.2 Training schema____________________________________________________________ 4

1.3 Trans
-
IND outcomes include___________________________________________________5

1.4 Trans
-
IND workflow__________________________________________________________6

2. The Bridge story______________________________________________________________ _7

2.1 Tender___________________________________________________________________ _7

2.2 Pre
-
normative_____________________________________________________________ _8

2.3 Detailed Design_____________________________________________________________9

2.4 Scheduling________________________________________________________________10

2.5 Plant Layout_______________________________________________________________11

2.6 Beam Manufacturing________________________________________________________ 12

2.7 QC
-

Laser Scanner_________________________________________________________ 13

2.8 QC


NDT________________________________________________________________ 14

2.9 Finishing operations________________________________________________________ 15


Training material, courses and workshops deployment

3



Training material, courses and workshops deployment

Table of contents

2.10 Diaphragm manufacturing__________________________________________________ 16
2.11 Pre
-
slab Manufacturing____________________________________________________ 17

2.12 Pre
-
slab
Inspection
________________________________________________________18

2.13 Closed cap profiles________________________________________________________19

2.14 Manufacturing of acoustic barriers____________________________________________ 20

2.15 On
-
site Assembly_________________________________________________________ 21

2.16 QRCodes_______________________________________________________________ 22

2.17 Intelligent Positioning System________________________________________________23

2.18 Beam
-
Deck Joint_________________________________________________________ 24

2.19 Assembly of Safety Barriers_________________________________________________25

2.20 Operational bridge________________________________________________________ 26

2.21 Bridge Maintenance and Demolition___________________________________________27

2.22 Trans
-
IND system improvements in term of cost effectiveness______________________ 28

3. Additional Training materials____________________________________________________ 29

4. Training material, courses and workshops developed during the project___________________30


4



1
.

Training

programme

1
.
1

Training

resources

Different resources have been used to produces training material, each partner have chosen the
resource that better shows the results developed.

The

resources

developed

include
:


Written materials and documents.


Theoretical courses and modules that will be used in traditional learning context.


Practical courses

o
In the demonstration site

.

o
Through mobile and virtual demonstrators



Web based distributed e
-
learning modules.

These

resources

will

benefit

from

all

the

research

and

demonstration

materials

(multimedia

materials,

public

project

deliverables,

etc
.
)

1
.
2

Training

scheme


The

training

material

has

been

organized

in

a

logical

sequence

evolution

of

an

example

of

Bridge

production

request

(description

in

first

person)
.

For

each

step

of

the

Bridge

story

evolution

video

and

specific

training

materials

there

are
.

A

list

of

additional

training

material

not

directly

connected

with

the

Bridge

story

evolution

there

are

at

the

end
.

Training material, courses and workshops deployment

5



1.3 Trans
-
IND outcomes include


Design


Manufacturing processes and resulting parts


Inspection and QC methods and apparatus


Assembly processes


Logistics and planning


Software tools

Training material, courses and workshops deployment

6



Training material, courses and workshops deployment

1
.4 Trans
-
IND workflow

7



2. The Bridge story
-


2.1 Tender

Tender

The life of a bridge starts with the tender phase.

8



2.1 The Bridge story
-


2.2 Pre
-
normative

Pre
-
normative Research


Training material:

Pre
-
normative Research and Recommendation
for Standardization in FRP Bridge

We have heard many times the word rule. On what are they based?
The rules of the configurator are based on norms and standards

The design, production and construction of infrastructure objects must follow the rules
of EU (European Union) legislation. Eurocode for FRP does not yet exist and to easier
navigate among existing normative documents a tool has been developed
-

a database
of existing normative documents for FRPs have been created containing titles and
short summaries of standards, recommendations and guidelines dealing with FRPs

9



2.1 The Bridge story
-


2.3 Detailed Design


Beam


Pre
-
slab


Diaphragms

What

is

considered

in

detailed

design


Type of Resin, Fiber,
Core, etc.


Laminating sequence


Number of layers, etc.

Detailed Design

Non
-
standard elements

Standard elements





Once the tender is accepted, the project department communicates to the design
department to start the detailed design procedure

load
-
bearing elements

non load
-
bearing elements


Safety barriers


Acoustic barriers


….

10



2.1 The Bridge story
-


2.4 Scheduling

Scheduling

Once the detailed design is finished, it is time to schedule the manufacturing
and assembly of the bridge

Training material:

New innovative processes for structural elements in
composite materials for transport infrastructures

11



2.1 The Bridge story
-


2.5 Plant Layout

Introduction
Plant layout

After the project launch and the detailed design of the required bridge components,
the production area and the manufacturing plant has to be planned

In the past, the main manufacturing steps were performed manually and in different
production sites, which leads to longer construction times etc. In order to fulfill the
customer`s requirements (high demand; fast delivery) and to speed up the whole
construction time, new machinery and new concepts to atomize the whole
manufacturing process has to be developed. This machinery and concepts have to
be holistically planned in one single production site/factory.

Training material:

Conceptual Design of an Off
-
Site
Industrialisation Process for FRP components

12



2.1 The Bridge story
-


2.6 Beam Manufacturing

Beam Manufacturing

Training material:

Fiber Reinforced Plastic Beam Manufacturing
Process
-

Filament Winding

13



2.1 The Bridge story
-


2.7 QC
-

Laser Scanner

QC 3D Laser scanner

After production, FRP beam manufacturer needs to inspect the quality of the product. It is possible to use
Dimensional and morphological control via laser technology that aims to obtain complete information
about the geometry of the FRP components under inspection.

Training material:

Dimensional and morphological control system
based on 3D laser scanning

14



2.1 The Bridge story
-


2.8 QC
-

NDT

QC NDT

Once the Beam of the bridge has been realized we have to verify its structural integrity.

Training material:

Non
-
Destructive Techniques for Complex Composite
Components

If there are some defects, they will be checked whether or not they can be repaired.
If they fall under the category of repairable defects, they will be repaired as per the
respective procedures and NDT quality control check is done on the repaired area

15



2.1 The Bridge story
-


2.9 Finishing operations

Finishing operations

Once the beam is inspected, the beam is translated to a final area inside the factory,
where the finishing operations will be done, and it is placed on a support structure.

16



2.1 The Bridge story
-


2.10 Diaphragm manufacturing

Diaphragm Manufacturing

While the manufactured beam was being finished, the diaphragms were made in
parallel. Now, depending on the detailed design, it will be decided to go either for
externally or internally bonded diaphragms. In this case study internally bonded
diaphragms are take into consideration

17



2.1 The Bridge story
-


2.11 Pre
-
slab Manufacturing

Pre
-
slab Manufacturing

Since these bridge components are being made in one facility utilizing different
processes independent from each other, the respective can be made in parallel.
Another FRP element which is being manufactured is the pres
-
lab. Pre
-
slabs and
deck are synonyms and either of the two could be used.

18



2.1 The Bridge story
-


2.12 Pre
-
slab Inspection

Pre
-
slab Inspection

Since pre
-
slab manufacturing is a continuous process, hence they are
inspected online.

19



2.1 The Bridge story
-


2.13 Closed cap profiles

Closed cap profiles

Some security elements of the bridge are also made of FRP. This is the case of
closed cap profiles for safety barriers

Training material:

Safety barriers

20



2.1 The Bridge story
-


2.14 Manufacturing of acoustic barriers

Manufacturing of
acoustic barriers

Last FRP elements to be manufactured, if needed, are acoustic barriers

21



2.1 The Bridge story
-


2.15 On
-
site Assembly

At this point, all elements of the bridge are manufactured. They have to be
transported to the assembly site and mounted together

Advantages of FRP
parts for on
-
site
Assembly:



Lightweight


Lightweight crane


More beams per
truck


Leads to reduction of
cost installation

22



2.1 The Bridge story
-


2.16 QRCodes

QRCodes

The light weight of FRP parts eases bridge assembly. Other outcomes of
Trans
-
IND make it even easier. One example is QRCodes

23



2.1 The Bridge story
-


2.17 Intelligent Positioning System

Intelligent Positioning
System

Once the site manager has the information about how to place a beam, it is
time to position it

24



2.1 The Bridge story
-


2.18 Beam
-
Deck Joint

Beam
-
Deck Joints

When beams are placed, the pre
-
slabs have to be assembled and properly
joined to support the concrete.

Training material:

Testing

of FRP
joints

25



2.1 The Bridge story
-


2.19 Assembly of Safety Barriers

Assembly of Safety
Barriers

Once pre
-
slabs are mounted and concrete poured and cured, safety barriers
can be installed on the bridge

26



2.1 The Bridge story
-


2.20 Operational bridge

During this bridge story we have seen various tests performed on individuals
elements of the bridge. Now is the time of testing the entire bridge before it is put
into operation.

The test that we are about to perform on the newly finished bridge is a real scale
load test in witch loaded truck are past over the bridge.

Before the bridge
is actually put into
operation, a real
scale test is
performed which
in this case is
passing of loaded
trucks as per the
respective
norms/standards.

27



2.1 The Bridge story
-


2.21 Bridge Maintenance and Demolition

Bridge Maintenance
and Demolition

Once this bridge is set on operation, it undergoes preventive and periodic
maintenance as per the respective standards. Knowledge management tool is
used to access previous data, collect new data and keep record of the history of
the bridge.

28



2.1 The Bridge story
-


2.22 Trans
-
IND system improvements in term of cost effectiveness

Cost factors

Addressed in

Trans
-
IND

(as shown in “Bridge Story”)

Degree

of i
mproved

c
ost
effectiveness

Labour


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Labour safety

Significant

Material


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29



3. Additional Training materials


FRP Bridge



This presentation describes the experience of an infrastructure company on the
realization of the FRP bridge.


Use of Composite in Infrastructure Application


This presentation focussing on different composite material using to produce
structural components with pultrusion technique.


Epoxy Resin for Composite and Adhesive Application
”. A guide to choose the
correct resin for different techniques of FRP production.


Asset management, co
-
makership and

Performance
-
based business
models for FRP bridges
”.

Need for a new business model for FRP bridges, an asset management and
co
-
markership concepts and market opportunities have been described.


Trans
-
IND Catalogue


In the catalogue there are the characteristics of all components of the Bridge

30



4. Training material, courses and workshops
developed during the project

Courses and
Training

planned

Format

available

Date/ Place

Trans
-
IND Partner
organizer

Topic

Audience/Interested

PDF
presentation

23 March 2012
/ Ancona, Italy

UNIVPM workshop


New Industrialized Construction Process for Transport Infrastructures Based
on Polymer composite Components


The objective is to discuss about new
findings and future trends in this important industrial application and the use of
new material in the construction sector.

Università Politecnica delle
Marche,
engineers,
researchers, PhD students.

PDF
presentation

14
th

December
2012 /
Ljubljana,
Slovenia

ZRMK workshop


New

Industrialized

Construction

Process

for

Transport

Infrastructures

Based

on

Polymer

composite

Components


The

workshop

purpose

is

presentation

of

the

project,

dissemination

of

knowledge

gained

through

research

on

FRP

and

preliminary

project

results

University of Lijbliana,
engineers, technical people,
professionals from
Construction
sector,
researchers, students
.

PDF
presentation

15
th

February
2013 / Madrid,
Spain

Acciona
Infrastructure

workshop


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The workshop offers a great opportunity to learn more about composite
materials and the possibilities they offer

to the infrastructure sector
.

Universidad
Politécnica

de
Madrid,

All
players in the
composite
sector:

researchers
, universities,
material suppliers

PPT
presentation

May 2013/
Ancona, Italy

UNIVPM course


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獴sdents

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engineer

course)

PPT
presentation

2
nd

Quarter

of

2013
,

Stuttgart,

Germany

Fraunhofer
IPA
course


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Describe

the

logical

distribution

of

places,

machines

and

transferring

information
.

Master

students

/

PhD

students

PPT
presentation

2013
/Dresden,

Germany

TUD

course

Software

systems,

simulation

and

monitoring

of

engineering

systems

courses

(RFID

use

in

construction)
.

MSc
.

Students